JP2016533614A - Voltage-to-light conversion device - Google Patents

Abstract

The present invention relates to a voltage-to-light conversion device 1 such as an OLED comprising a structured conductive layer 3 on a substrate 2 and a further layer 60 which is part of a sealing part and includes a layer edge. The conductive layer includes a structural edge 10 in an edge region 70 near the layer edge, and at least a portion of the structural edge is not perpendicular to the layer edge. In the edge region, since at least a part of the structural edge is not perpendicular to the layer edge, during the production process for making further layers, the possible flow along the structural edge of the initially liquid layer material is liquid The material is oriented to remain relatively close to the desired layer edge, i.e. the liquid material may be better localized locally.

Description

  The present invention relates to a voltage-to-light conversion device such as an organic light emitting device (OLED) or an organic photovoltaic device (OPVD). Furthermore, the present invention relates to a substrate for a voltage-to-light conversion device.

  An OLED typically includes a structured ITO layer on a glass substrate that forms a first electrode, and an organic light emitting element disposed between the second electrode and the first electrode and the second electrode. And further includes a material. The OLED further includes a thin film encapsulant formed by a stack of various layers for encapsulating at least the organic light emitting material, the stack of thin film encapsulant comprising an inorganic layer, eg, a SiN layer, and a polymer layer During the OLED manufacturing process, the inorganic layer is applied in a chemical vapor deposition (CVD) process and the polymer layer is applied locally on the inorganic layer in a wet chemical process such as inkjet printing. During the wet chemical process, the polymer layer may not remain locally confined within the edge region where the polymer layer edge is to be formed, i.e., the polymer layer may undesirably spread.

  The object of the present invention is that a layer made of a material that is liquid during the manufacturing process for manufacturing a voltage-to-light conversion device is better localized locally in the edge region where the edge of the layer is to be formed. It is to provide a voltage-to-light conversion device that can be manufactured to be limited. It is a further object of the present invention to provide a substrate for a voltage-to-light conversion device, a manufacturing apparatus and method for manufacturing the voltage-to-light conversion device, and a manufacturing apparatus and method for manufacturing the substrate.

  In the first aspect of the present invention, the voltage-light conversion is performed between the first electrode and the second electrode and is performed between the first electrode and the second electrode. A voltage-to-light conversion device comprising a material and at least a seal for sealing the voltage-to-light conversion material, the seal having a layer edge and manufacturing the voltage-to-light conversion device A voltage-to-light conversion device is presented that includes an additional layer made of a material that is liquid during the process. The voltage-to-light conversion device further includes a structured conductive layer on the substrate, wherein at least one of the first electrode and the second electrode is formed by the structured conductive layer, or Electrically connected to the structured conductive layer. The structured conductive layer includes a structural edge in the edge region, and the edge region also includes a layer edge of an additional layer included in the seal. In the edge region, at least a part of the structured edge of the structured conductive layer is not perpendicular to the layer edge of the further layer contained in the seal.

  The difficulties associated with the local limitation of the liquid material used to make a layer having a layer edge into the edge region where the layer edge is to be formed are entirely straight and perpendicular to the layer edge. It has been found that this is caused by the flow of liquid material along the straight structural edges. In the edge region, if at least a portion of the structure edge is not perpendicular to the layer edge, the flow of liquid material along the structure edge can be redirected so that the liquid material stays closer to the desired layer edge. In this manner, the liquid material can be better localized locally within the edge region.

  In the edge region, the whole structure edge or only a part of the structure edge is not perpendicular to the layer edge. In an embodiment, the edge region is defined as not covered by a layer and having a boundary parallel to the layer edge, and the distance between this boundary and the layer edge is preferably 4 mm or less, more preferably Is 3 mm or less, more preferably 2 mm or less. The portion of the structural edge that is not perpendicular to the layer edge is preferably at least partially located between the layer edge and the parallel boundary of the edge region.

  At the position of the structural edge, the generally regular layer edge is still slightly disturbed by unwanted solidified layer material that flows along the structural edge during the manufacturing process, but this adverse effect is strongly influenced by the shape of the structural edge. Reduced to Note that when this is the case, the term “not perpendicular to the layer edge” refers to a regular layer edge and not a slight perturbation of the layer edge at the location of the structure edge.

  Voltage-to-light conversion materials convert voltage to light or convert light to voltage. In the first case, the voltage-to-light conversion device is, for example, an OLED, and in the second case, the voltage-to-light conversion device is, for example, OPVD. Preferably, the structured conductive layer is an indium tin oxide (ITO) layer on a substrate, preferably a glass substrate.

  Preferably, in the edge region, the structural edge comprises a first part that is not perpendicular to the layer edge and an adjacent second part that, together with the first part, surrounds an angle in the range of 45 degrees to 135 degrees. Including. The first part of the structural edge is preferably closer to the layer edge than the second part. The angle surrounded by the first part and the second part is, for example, 90 degrees. Such a structural edge very effectively limits the liquid material for forming the layer in the edge region during the manufacturing process.

  Preferably, the structural edge is a serpentine edge such that at least a portion of the structural edge is not perpendicular to the layer edge, ie, preferably includes a serpentine edge that is not perpendicular to the layer edge. Is used as the structural edge. The serpentine edge preferably includes at least one 90 degree location where two adjacent portions of the edge surround a 90 degree angle. The edge may include a plurality of 90 degree locations to form a serpentine shape. Thus, the edge includes a 90 degree angle or 90 degree curvature, which very effectively redirects the liquid flow so that the liquid flow is better defined within the edge region. However, the serpentine edge may be shaped differently. For example, the serpentine edge may be formed by a semicircular portion.

The sealing part is preferably a thin film sealing part including a plurality of layers. The sealing part preferably includes a polymer layer and an inorganic layer. In particular, the sealing portion includes a polymer layer between two inorganic layers such as Al ₂ O ₃ , Si _x O _y , Si _x N _y , TiO ₂ , ZrO ₂ , and the layer edge is formed by the polymer layer. It is formed. However, the sealing part may be formed by another layer, for example by another polymer layer and / or a layer of voltage-light converting material. The voltage-to-light conversion material preferably comprises an organic voltage-to-light conversion material. Voltage-to-light conversion materials include stacks of various layers. For example, if the voltage-to-light conversion device is an OLED, the voltage-to-light conversion material is necessary to generate multiple layers of radiation that emit different colors and, optionally, the appropriate energy level, ie light. And a further layer for providing electrons and holes of the energy level assumed.

  The structured conductive layer is preferably structured by a groove including a structural edge. The width of the groove varies along the extension of the groove. In particular, the groove includes a wide portion having a larger width and a narrow portion having a smaller width. A series of narrow portions including serpentine edges are disposed between the two wide portions. The wide portion has a width of 3 mm, and the narrow portion has a width of 0.25 mm. The groove may alternately include a series of three parallel narrow portions that are parallel to the layer edges and two vertical narrow portions that are perpendicular to the layer edges.

  In a second aspect of the invention, a substrate for manufacturing a voltage-to-light conversion device according to the first aspect, wherein the substrate comprises a structured conductive layer, and the structural edge is a serpentine edge, A substrate is presented.

  It should be understood that the voltage-to-light conversion device according to the first aspect and the substrate according to the second aspect have similar and / or identical preferred embodiments, in particular as defined in the dependent claims.

  It is to be understood that preferred embodiments of the invention may be any dependent claim or any combination of the above embodiments with each independent claim.

  These and other aspects of the invention will be apparent from and elucidated with reference to the embodiments described hereinafter.

1 schematically and exemplarily shows an OLED. 2 schematically and exemplarily shows a cross-sectional view of the OLED shown in FIG. 1 schematically and exemplarily shows a portion of an OLED. FIG. 4 schematically and exemplarily shows a cross-sectional view of a portion of the OLED shown in FIG. 3. 1 schematically and exemplarily shows an embodiment of an OLED according to the invention; 6 schematically and exemplarily shows a portion of the embodiment shown in FIG. Fig. 2 schematically and exemplarily shows a part of another embodiment of an OLED according to the invention. 1 schematically and exemplarily shows a production apparatus for producing an OLED. 5 shows a flowchart exemplarily illustrating an embodiment of a manufacturing method for manufacturing an OLED. Various serpentine edges are schematically and exemplarily shown.

  FIG. 1 schematically and exemplarily shows an embodiment of an OLED. FIG. 2 schematically and exemplarily shows a cross-sectional view of this OLED along the line indicated by AA. The OLED 101 includes a substrate 2 having a structured conductive layer 3 which is preferably an ITO layer.

  The conductive layer 3 forms a first electrode. The OLED 101 further includes a second electrode 5 that is a metal electrode, and the organic light emitting material 4 is disposed between the first electrode 3 and the second electrode 5. A voltage source 8 is connected to the first electrode 3 and the second electrode 5 via the electrical connection 7, and the organic light emitting material 4 applies a voltage to the first electrode 3 and the second electrode 5. Emits light when done.

  The OLED 101 further includes a thin film sealing portion for sealing at least the organic light emitting material 4 in order to protect the organic light emitting material 4 against the influence of water vapor and other environments. The thin film encapsulation is formed by a stack of various layers 6, 60, 61. In this embodiment, the thin film sealing portion is formed by the first barrier layer 6, the intermediate layer 60, and the second barrier layer 61. The first barrier layer 6 and the second barrier layer 61 are inorganic layers. The intermediate layer 60 is a polymer layer. The intermediate layer 60 protects the second electrode 5 that is considered to be a cathode layer and the inorganic layer 6. The intermediate layer 60 is a water repellent layer for avoiding water intrusion into the organic light emitting material 4. The intermediate layer 60 may be a drainage layer. The intermediate layer 60 may further provide scratch protection, provide a light input function, and / or provide a light output function.

  FIG. 3 schematically and exemplarily shows a portion of the OLED shown in FIGS. 1 and 2. As can be seen in FIG. 3, a straight groove 109 having a straight structure edge 110, which is perpendicular to the layer edge 63, is formed in the edge region 70 including the layer edge 63 of the intermediate layer 60. During the manufacturing process for manufacturing the OLED 101, a liquid intermediate layer material is used to make the intermediate layer 60, and the liquid intermediate layer material has a structure edge that is linear from the layer edge 63 in the direction of the path. 110 flowed along. This results in an undesirable spilled component 69 at the layer edge 63 of the intermediate layer 60.

  FIG. 4 schematically and exemplarily shows a cross-sectional view of the substrate 2 with the structured conductive layer 3 including the grooves 109 after the first barrier layer 6 and the intermediate layer 60 have been applied. As shown in FIG. 4, the first barrier layer 6 very closely follows the contour of the groove 109. Thus, when the intermediate layer 60 is applied on top of the first barrier layer 6, the structure of the ITO layer 3 is still clearly visible, resulting in unwanted spillage.

  For this reason, the OLED according to the present invention has a structural edge having a portion that is not perpendicular to the layer edge 63 of the intermediate layer in the edge region 70, as schematically and exemplarily shown in FIGS. including.

  Embodiment 1 of an OLED according to the invention, schematically and exemplarily shown in FIGS. 5 and 6, also comprises a substrate 2 having a structured conductive material 3, an organic light emitting material 4, a second electrode 5, And sealing portions 6, 60, 61. However, in embodiment 1 according to the invention, the structure of the conductive layer 3 comprises a serpentine edge 10 in the edge region 70 where the layer edge 63 of the intermediate layer 60 is located. In this edge region, the sealing part reaches the structured conductive layer 3.

  The serpentine edge 10 has at least one of a vertical portion of the edge 10 that is perpendicular to the periphery of the sealing portion and a parallel portion of the edge 10 that is parallel to the periphery of the sealing portion at an angle of 90 degrees. Including two 90 degree locations 11. The edge 10 includes a plurality of 90 degree locations 11 to form a serpentine shape. The edge 10 is the edge of the groove 9, and in this embodiment, the width of the groove 9 varies along the extension of the groove 9. In particular, the groove 9 includes a wide portion 12 having a larger width and a narrow portion 13 having a smaller width.

  FIG. 7 schematically and exemplarily shows a further embodiment of a serpentine structure formed by an edge 23 of conductive material. In this embodiment, the serpentine structure includes a series of narrow portions 213 of the groove 209 that include a serpentine edge 210 between the two wide portions 212, 214 of the groove 209. Further, the wide portion 214 is disposed between the series of narrow portions 213 and the further narrow portion 225. The wide portions 212 and 214 have a width 24 of 3 mm, and the narrow portion 213 has a width 18 of 0.25 mm. The distance 15 between the two parallel narrow portions of the groove between the wide portions 212 and 214 is 1 mm. Furthermore, the distance 16 between the edge 20 of the intermediate layer 60 and the closest parallel narrow portion is 0.3 mm. In other embodiments, the serpentine structure may include other dimensions. FIG. 7 further shows the edge 19 of the cathode layer 5 and the edge 21 of the barrier layers 6, 60.

  FIG. 8 schematically and exemplarily shows a manufacturing apparatus for manufacturing the OLED 1. The manufacturing apparatus 30 includes a substrate providing unit 31 for providing the substrate 2 with a structured conductive layer including serpentine edges. In this embodiment, the substrate providing unit 31 provides a structured ITO layer on the substrate 2 that includes a groove with serpentine edges. In FIG. 8, the resulting substrate having a structured conductive layer is indicated by reference numeral 40. The substrate providing unit 31 applies a subtractive technique to a substrate which is a glass or polymer substrate entirely covered with ITO in order to generate a structure in the ITO layer. Subtractive techniques are, for example, laser ablation, edge paste printing, photolithography and the like. In another embodiment, the substrate providing unit 31 is structured on the substrate, for example, by sputtering a conductive material through a shadow mask and by printing such as gravure printing, flexographic printing, inkjet printing, screen printing, etc. Applying the conductive layer in a structured manner creates a substrate having a structured conductive layer.

  The manufacturing apparatus 30 further includes a voltage-to-light conversion material and an electrode providing unit 32 for disposing the organic light emitting material between the first electrode and the second electrode formed by the structured conductive layer. Including. In this embodiment, the voltage-to-light conversion material and electrode providing unit 32 includes an organic light-emitting material, a first light-emitting material, and a second electrode to provide a structure in which the organic light-emitting material is disposed between the first electrode and the second electrode. A metal material for forming the two electrodes is deposited on the structured conductive layer. The resulting substrate having a structured conductive layer, an organic light emitting material, and a second electrode is indicated by reference numeral 41. The voltage-light converting material and electrode providing unit 32 deposits an organic light emitting material, for example, by vacuum evaporation, and deposits a second electrode, preferably forming a cathode, by vacuum sputtering. However, the organic light emitting material and the metal material forming the second electrode may be deposited using other techniques.

  The manufacturing apparatus further includes a sealing portion providing unit 33 for providing a thin film sealing portion. In particular, the sealing unit providing unit 33 provides various layers of the thin film sealing unit. For example, an inorganic layer is applied by a CVD process or an atomic layer deposition (ALD) process, and a polymer layer is locally applied onto the inorganic layer in a wet chemical process such as inkjet printing. The CVD process produces an inorganic layer according to the contour of the structured conductive layer. Since the polymer layer is applied using a wet chemical process such as ink jet printing, the correspondingly applied liquid material can flow along undesired areas on the substrate along the straight edges of the structured conductive layer. There is. However, thanks to the serpentine edge of the structured conductive layer, this flow of liquid material is better limited to the edge region where the desired edge of the polymer layer should ultimately exist. Turned around. Since the sealing portion providing unit 33 provides a polymer layer that ultimately forms a layer edge in the edge region, the sealing portion providing unit 33 provides a layer of OLED such that a layer edge is formed in the edge region. Can be considered as a layer providing unit.

  The sealing unit providing unit 33 provides an inorganic layer formed by CVD, physical vapor deposition (PVD), ALD, or the like, and a polymer layer formed by coating or printing such as gravure printing, flexographic printing, inkjet printing, or silk screen printing. The sealing portion providing unit 33 performs a series of chemical vapor deposition and coating or printing a plurality of times to form a sealing portion made of a plurality of layers.

  By better and locally limiting the liquid material during the manufacturing process, the quality of the liquid material application, in particular the spatial accuracy of the liquid material application, is improved and the layer formed by the liquid material Application of further layers on top of the can be simplified.

  The manufacturing apparatus 30 may include additional units for providing additional components to the OLED, such as wires for providing additional layers, electrical connections to a voltage source. The substrate providing unit 31 can be regarded as a processing apparatus for providing a structured conductive layer on a substrate such that the structured conductive layer includes serpentine edges.

  In the following, an embodiment of a manufacturing method for manufacturing an OLED will be exemplarily described with reference to the flowchart shown in FIG.

  In step 101, a substrate is provided having a structured conductive layer including serpentine edges. In particular, an ITO layer on a glass substrate is provided in which the ITO layer includes serpentine edges. In step 102, organic light emission is performed to produce a structure that includes an organic light emitting material between the structured conductive layer forming the first electrode and the second electrode formed by the applied metal material. Materials and metallic materials are applied to the structured conductive layer. In step 103, the thin film encapsulant is provided so that the thin film encapsulant encapsulates at least the organic light emitting material. In step 104, the electrodes are provided with an electrical connection to connect the first electrode and the second electrode to a voltage source.

  Step 101 is considered to be a processing method step for processing a substrate such that a structured conductive layer comprising serpentine edges is provided on the substrate. The steps of the manufacturing method are performed in particular automatically by the manufacturing apparatus described above with reference to FIG. 8, or these steps may be performed at least partly manually.

  Grooves in the structured conductive material are used as electrode spacing, in particular anode-cathode spacing, where the first electrode is formed by the first portion of the structured conducting layer and the second electrode is voltage A second part is used to connect to the source. The outflow of liquid material can also be caused by capillary forces, and this outflow can be minimized by the serpentine structure of the groove and the corresponding serpentine structure of the edge of the groove.

  The serpentine edge structure of the conductive layer is particularly useful when a thin film encapsulation of the polymer layer is applied. If the OLED comprises an ITO / inorganic / polymer / inorganic structure, the edge region containing this structure is preferably serpentine to reduce the spillage of polymer material that may occur at the desired seal periphery during the manufacturing process. The edges are arranged. If a serpentine structure is not used, the outflow must be wider, i.e. a wider periphery must be used.

  The substrate preferably includes ITO regions with serpentine edges having a curvature of about 90 degrees, rather than ITO regions with straight edges. Having an ITO layer with such serpentine edges strongly limits areas where liquid material such as polymer layers can flow out. The structured conductive material includes one or more serpentine edges and corresponding grooves. In particular, there may be a plurality of edge regions on the substrate, each edge region including one or more serpentine edges.

  In the embodiments described above, a substrate having a structured conductive layer that includes a serpentine edge is used to manufacture an OLED, while in another embodiment, a structured conductor that includes a serpentine edge. The substrate with the layer may be used to manufacture another voltage-to-light conversion device such as OPVD.

  In the embodiments described above, the serpentine-type edge provides a reduced outflow of liquid sealing material, while in other embodiments, the serpentine-type edge is particularly suitable for other liquid polymer materials such as polymer hole injection layer materials. It may be used to reduce the outflow of other liquid materials that are materials.

  In the embodiments described above, the layer edges located in the respective edge regions where the structural edges are present are generally straight, but in other embodiments the layer edges may have other shapes, for example The layer edge may be curved.

  In the embodiments described above, the conductive layer includes a specific structure having a specific structural edge, but in other embodiments, the conductive layer may include another structure having a different structural edge. For example, the conductive layer has one or more serpentine structures 309, 409, 509 shown schematically and exemplarily in FIG. The structural edge may be an L-shaped edge.

  Other variations of the disclosed embodiments can be understood and attained by those skilled in the art from a study of the drawings, the specification, and the appended claims, in carrying out the claimed invention.

  In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality.

  A single unit or device may fulfill the functions of several items recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measured cannot be used to advantage.

  The procedure performed by one or more units or devices, such as providing a structured conductive layer on a substrate, providing a voltage-to-light conversion material, providing an electrode, providing a seal, etc., is any other number May be executed by any unit or device. For example, steps 101 through 104 may be performed by a single unit or performed by any other number of various units. Control of a manufacturing apparatus for manufacturing a voltage-light conversion device by these procedures and / or a manufacturing method for manufacturing a voltage-light conversion device, and / or processing a substrate by a processing method for processing a substrate The control of the processing device for doing so may be implemented as program code means of a computer program and / or as dedicated hardware.

  The computer program may be stored / distributed on a suitable medium, such as an optical storage medium or solid state medium, supplied with or as part of other hardware, but may be internet or other wired or wireless It may be distributed in other formats, such as via a telecommunication system.

  Any reference signs in the claims should not be construed as limiting the scope.

The present invention relates to a voltage-to-light conversion device, such as an OLED, comprising a structured conductive layer on a substrate and a further layer that is a layer of the encapsulant and includes a layer edge. The conductive layer includes a structural edge in an edge region near the layer edge, and at least a portion of the structural edge is not perpendicular to the layer edge. In the edge region, since at least a part of the structural edge is not perpendicular to the layer edge, during the production process for making further layers, the possible flow along the structural edge of the initially liquid layer material is liquid The material is oriented to remain relatively close to the desired layer edge, i.e. the liquid material may be better localized locally.

Claims (9)

A first electrode;
A second electrode;
A voltage-to-light conversion material that performs voltage-to-light conversion and is disposed between the first electrode and the second electrode;
A sealing portion for sealing at least the voltage-light converting material;
A voltage-to-light conversion device comprising:
The seal includes a further layer having a layer edge, made of a material that is liquid during the process for manufacturing the voltage-to-light conversion device;
The voltage-to-light conversion device further includes a structured conductive layer on a substrate, wherein at least one of the first electrode and the second electrode is formed by the structured conductive layer. Or electrically connected to the structured conductive layer,
The structured conductive layer includes a structural edge in an edge region, the edge region also including the layer edge of the further layer;
In the edge region, at least a part of the structural edge of the structured conductive layer is not perpendicular to the layer edge of the further layer;
Voltage-light conversion device.   The voltage-to-light conversion device of claim 1, wherein the structural edge is a serpentine edge such that at least a portion of the structural edge is not perpendicular to the layer edge.   In the edge region, the structural edge is adjacent to a first part that is not perpendicular to the layer edge and an adjacent second part that surrounds an angle in the range of 45 degrees to 135 degrees with the first part. The voltage-light conversion device according to claim 1, comprising:   The voltage-to-light conversion device according to claim 1, wherein the voltage-to-light conversion material includes an organic voltage-to-light conversion material.   The voltage-to-light conversion device according to claim 1, wherein the layer edge is an edge of a polymer layer.   The voltage-to-light conversion device according to claim 1, wherein the structured conductive layer is structured by a groove including the structure edge, and the width of the groove varies along the extension of the groove.   The groove includes a wide portion having a larger width and a narrow portion having a smaller width, and a series of the narrow portions are disposed between the two wide portions, and the structural edge includes the width The voltage-to-light conversion device according to claim 6, wherein the voltage-to-light conversion device is a meandering edge formed by the narrow portion.   The voltage-to-light conversion device according to claim 1, wherein the conductive layer is an ITO layer. 2. A substrate for manufacturing a voltage-to-light conversion device according to claim 1, wherein the substrate comprises the structured conductive layer, and the structural edge is a serpentine edge.

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